Extruded fence post and modular fence assembly

ABSTRACT

A fence assembly includes a plurality of spaced, elongated hollow post members. Each of the plurality of elongated post members has an outer wall. The outer wall has a generally H-shaped cross-section. The elongated post member includes a first side and a second side. The first and second sides are oriented opposite each other. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated hollow post member. One or more reinforcing member may be positioned in the middle chamber of one or more of the plurality of elongated hollow members to provide support. A plurality of fence panels is fastened between adjacent pairs of the plurality of spaced, elongated post members.

FIELD OF THE INVENTION

[0001] The present invention relates to an extruded plastic modular fence assembly including a novel post member for use with various combinations of rails, pickets, raft members, spacers, panels, filler members and channel members. The post member is designed to be used with an optional internal reinforcing member in high-stress areas of the fence assembly adjacent, for example, fence gates.

BACKGROUND OF THE INVENTION

[0002] Fencing is available in a number of materials and designs to be typically used to restrict entry to a piece of land, to provide privacy and/or provide decorative landscape accents. It is often an object of fencing to provide these benefits, while being sturdy, maintenance free and aesthetically pleasing as well.

[0003] Until recently, wood components have been assembled into fences in an attempt to fulfill the above requirements. Wood fences are strong, relatively easy to install and pleasing to view. However, wood fences tend to be expensive, prone to decay in moist conditions and require periodic maintenance if expected to achieve a reasonable lifespan.

[0004] The deficiencies of wood fencing have been addressed to some extent by using alternate materials and construction methods. For example, molded or extruded plastic fence elements have been used with some success. While, plastic can provide good resistance to challenges like extended exposure to moisture, ordinary hollow, plastic posts and other plastic members may lack the strength and durability to resist strong winds, and support heavy loads from gates and heavy ice and snow, for example.

[0005] There is a demand for a modular plastic fence assembly that combines superior performance and low manufacturing and maintenance costs. The present invention satisfies the demand.

SUMMARY OF THE INVENTION

[0006] The present invention contemplates a fence assembly that may be assembled and selectively configured into a number of various forms due to the modular nature of the elements or components. The elements of the fence assembly are preferably formed of a polymeric material, such as plastic, by extrusion or molding, for example. The thickness of the sidewalls of the fence assembly components may be any desired thickness, preferably from about one-eighth of an inch to about one-quarter of an inch, such that the element is provided with sufficient physical rigidity and other properties. The components may be extruded or formed by any other suitable method. The material from which the fence components are made is preferably an extrudable thermoplastic material, such as polyvinyl chloride (PVC), including outdoor grade rigid PVC.

[0007] According to an aspect of the invention, a post for a fence assembly includes an elongated hollow member having an outer wall. The outer wall has a generally H-shaped cross-section and includes a first side and a second side. The first and second sides are oriented opposite each other on the elongated member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated member.

[0008] Other aspects of the invention may provide a first channel formed along the first side and a second channel formed along the second side. Both first and second channels are defined by the H-shaped cross-section. The one or more inner ribs may be a pair of spaced ribs. The first channel may include a first upper sidewall, a first inner sidewall and a first lower sidewall. The second channel may include a second upper sidewall, a second inner sidewall and a second lower sidewall. A first inner rib may extend between a first and second point on an inside surface of the outer wall. The first point may be located adjacent an intersection of the first upper sidewall and the first inner sidewall and the second point may be located adjacent an intersection of the second upper sidewall and the second inner sidewall. A second inner rib may extend between a third and fourth point on an inside surface of the outer wall. The third point may be located adjacent an intersection of the first inner sidewall and the first lower sidewall and the fourth point may be located adjacent an intersection of the second inner sidewall and the second lower sidewall. The middle chamber may have a rectangular cross-section. The first and second ribs and the first and second inner walls may define the middle chamber. The outer wall may include a generally planar third side and a fourth side of the elongated member.

[0009] Another aspect of the invention provides a post assembly for a fence including an elongated post member having an outer wall. The outer wall has a generally H-shaped cross-section defining a first channel along a first side of the elongated member and a second channel along a second side of the elongated member. The first and second sides are oriented opposite each other on the elongated member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated member. A reinforcing member is shaped and sized to be received within the middle chamber for reinforcing the post member.

[0010] Other aspects of the invention provide a rigid foot plate connected to a lower end of the reinforcing member. The foot plate may be adapted to be fastened to a footing.

[0011] Another aspect of the invention provides a fence assembly including a plurality of spaced, elongated hollow post members. Each of the plurality of elongated hollow post members has an outer wall. The outer wall has a generally H-shaped cross-section. The elongated post member includes a first side and a second side. The first and second sides are oriented opposite each other on the elongated post member. One or more inner rib is attached to an inner surface of the outer wall and extends between the first side and the second side to define a middle chamber of the elongated hollow post member. One or more reinforcing member is positioned in the middle chamber of one or more of the plurality of elongated hollow members to provide support. A plurality of fence panels is fastened between adjacent pairs of the plurality of spaced, elongated hollow post members.

[0012] Other aspects of the invention provide fence panel components fastened into the first and second channels. Filler members may be provided, which are sized and shaped to be received by one of the first channel and the second channel. The fence assembly may further include one or more channel member attachable to the elongated hollow post members and sized and shaped for receiving an edge of a fence panel.

[0013] These and other advantages, as well as the invention itself, will become apparent in the details of construction and operation as more fully described and claimed below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a side elevational view of one embodiment of a fence assembly according to the present invention;

[0015]FIG. 2 is a side elevational view of a mounted reinforcing member for a post according to one embodiment of the present invention;

[0016]FIG. 3 is a cross-sectional view of one embodiment of a post of the present invention;

[0017]FIG. 4 is a cross-sectional view on the post of FIG. 3 illustrated a technique for attaching fence panel components to the post;

[0018]FIG. 5 is a cross-sectional view of a channel member;

[0019]FIG. 6 is a cross-sectional view of a filler member;

[0020]FIG. 7 is a cross-sectional view of a board member;

[0021]FIG. 8 is a cross-sectional view of another embodiment of a board member with a tongue and groove configuration;

[0022]FIG. 9 is a cross-sectional view of a top rail member including a narrow channel;

[0023]FIG. 10 is a cross-sectional view of an intermediate rail member including a narrow channel and a relatively large channel member opposite the narrow channel; and

[0024]FIG. 11 is a cross-sectional view of a bottom rail member.

DETAILED DESCRIPTION OF A PRESENTLY PREFERRED EMBODIMENT

[0025] In the description that follows, like elements are marked throughout the specification and drawings with the same reference character, respectively. The drawing figures are not necessarily to scale. Further, description of the assembly and various elements, components or portions of the assembly are provided according to their orientation as depicted in the drawings and are not meant to be limiting in any way.

[0026] An embodiment of a portion of a fence assembly according to the present invention is presented generally at 10 in FIG. 1. Generally, fence assembly 10 includes a plurality of elongate post members, one of which is depicted at 12. It will be understood that the posts in any fence assembly may include one or more posts positioned at an end, corner or intermediate position in the assembly as necessary, depending on the configuration of the fence, i.e. number of ends, corners and the overall length of the fence assembly.

[0027] In the illustrated embodiment, an end post 12 is positioned at a left fence end 14 of the assembly 10. The post 12 is an elongate member generally having an H-shaped cross-section. The post 12 includes an optional central reinforcing member 13. Both the post 12 and reinforcing member 13 may be anchored by embedding within a standard concrete footing 15 or slab formed within or on the ground 17. The top 19 of the post 12 includes a cap member 21. The end post 12 may include an insert or filler member 18 (shown in FIG. 6) applied to a left channel 20 formed in left post side 26 opposite the right channel 24.

[0028] The reinforcing member 13 is intended to provide reinforcement to a post 12 in which the member 13 is inserted. The post 13, thus reinforced, may be used in any or all positions within an assembled fence. However, it will be understood that the post 12, thus reinforced, will preferably by used in areas of the fence where greater stresses are produced, such as at fence gate areas, fence ends, fence corners and so on. It ma be necessary, due to wind or snow conditions, for example, to provide every post 12 with a reinforcing member 13.

[0029] The end post 12 receives a panel, generally indicated at 16, which includes an assembly of various different fence components to form a plane extending between adjacent posts, as will be described more fully below. The panels 16 may include an assembly of many differing types of members. Typically, each panel will include rails that extend between posts positioned at top and bottom positions of each panel. Vertical pickets or horizontal boards may be attached or inserted between the top and bottom rails. Horizontal rails referred to as mid-rails or intermediate rails may be used along or between the top and bottom rails. Lattice members, and other various panel members may be substituted for vertical and/or horizontal boards.

[0030] The illustrated panel 16 extends from a right side 22 of the post 12. As will be described more fully below, the right post side 22 of post 12 is configured so as to present a vertical channel 24 along its length. The channel 24 is sized to receive the components of the panel 16. The panel 16 may include virtually limitless combinations of components to provide the various support and screening features of the fence assembly 10. Thus, the components illustrated herein should be considered as exemplary and not limiting in nature.

[0031] The panel 16 includes a bottom rail 30 positioned at a bottom edge 32 of the panel 16. The bottom rail 30 includes a bottom rail channel 34 formed horizontally along the span of the rail 30 and positioned at an upper edge 35 of the rail so as to receive components of the panel 16 and provide alignment and support.

[0032] The panel includes a plurality of extruded vertical board members 36. Lower edges 38 of the vertical board members 36 are disposed in the bottom rail channel 34. The vertical board members 36 are positioned parallel and edge-to-edge in the plane of the panel 16 and extend upwardly from the bottom rail 30.

[0033] Upper ends 40 of each of the plurality of vertical board members 36 are disposed in an under channel 42 formed in a lower edge 44 of intermediate rail 46. The under channel 42 is sized to receive the upper edges of the vertical board members 36. In the illustrated embodiment, the under channel 42 has a size, which is the same or similar to that of the bottom rail channel 34 to accommodate the vertical board members 36.

[0034] Intermediate rail 46 also includes an over channel 48 formed in an upper edge 50 of the intermediate rail 46. The over channel 48 may be the same or a different width as that of the under channel 42. As the name suggests, intermediate rail 46 extends horizontally at an intermediate position of panel 16, or in other words, at a position between top edge 52 and bottom edge 32 of panel 16.

[0035] A lattice member 54 may be positioned in the over channel 48 of the intermediate rail 46 and extends upwardly to be positioned in a bottom channel 56 of top rail 58. Top rail 58 effectively caps the panel at top edge 52.

[0036] The horizontal members, including bottom, intermediate and top rails 30, 46 and 58, are fastened to the post 12 by any suitable fastening mechanism. In a preferred embodiment, self-tapping screws (not shown) are inserted through the post 12 and corresponding horizontal or vertical members to engage and fasten the members to the post 12. Plugs 60 are used to plug the openings provided or created in the post 12 for the fasteners.

[0037] It will be understood that if the fence assembly includes corners, the assembly includes corner posts (not shown) adjoining angled panels of the fence assembly and, dependent upon the overall length of the fence, the assembly will include intermediate posts (not shown) joining adjacent panels of the fence.

[0038] An alternate anchoring technique is shown in FIG. 2. Reinforcing member 13 is welded or otherwise fastened to plate 62. Plate 62 may be a steel plate or other suitable material. Plate 62 is fastened to the concrete footing or slab by way of bolts or studs 64 or any other suitable fastener. Prior to the process of assembling the fence assembly, the footing 15 is poured. The plate 62 may be affixed to the footing 15 or if the plate is already fastened to the reinforcing member 13, the plate 62 and member 13 are fastened to the footing 15. In the alternate, the footing 15 is a concrete slab, or the like, which may be preferred to a footing in areas where digging is not convenient, for example. A post (not shown) is positioned upon the reinforcing member 13, and the remainder of the fence assembly is affixed to the post.

[0039] The post 12 of the present invention is illustrated in FIG. 3 wherein the post 12 includes an H-shaped continuous outer wall 66, which forms the H-shaped post. The post outer wall 66 defines an outer left channel 20 and an outer right channel 24. Each of the left and right channels 20, 24 is defined by an upper sidewall 71, an inner sidewall 72 and a lower sidewall 73. On sides of the post not occupied by channels are an upper outer face 74 and a lower outer face 75.

[0040] A pair of inner ribs 76, 77 extends from an inside surface 78 of the outer wall 66. A first rib 76 extends from a point where the left channel 20 upper sidewall 71L and inner sidewall 72L join to a point where the right channel 24 upper sidewall 71R and inner sidewall 72L join. The second rib 77 extends from a point where the left channel 20 inner sidewall 72L joins the lower sidewall 73L to a point where the right channel 24 inner sidewall 72R joins the lower sidewall 73R. The first and second ribs 76, 77 divide an interior compartment 79 (formed by the continuous outer sidewall) into an upper post compartment 80, a post middle compartment 81 and a lower post compartment 82.

[0041] The first and second ribs 76, 77 function to provide structural stiffness to the post 12 when used alone in a fence assembly and further provides the post with a middle compartment 81 sized and shaped to closely bracket the reinforcing member 13 (see FIG. 1). The reinforcing member 13 may be any suitable rigid reinforcing member. Preferably, the reinforcing member 13 is a galvanized steel rod, which is rectangular in cross-section, although any suitable material and cross-section may be used, for example, circular, oval, triangular, pentagonal and hexagonal.

[0042] It will be understood that the middle compartment 81 will be configured to closely match that of the reinforcing member 13 cross-section. In other words, if the member 13 is rectangular, the middle compartment 81 is defined by the ribs 76, 77 and inner wall 78 of left portion 72L and right portion 72R so as to be similarly rectangular. Likewise, if the member 13 is circular, the ribs 76, 77 and inner wall 78 will be designed and extruded so as to provide a circular middle compartment 81 to match that of member 13.

[0043] A technique for fastening various components to the post of FIG. 3 is illustrated in FIG. 4. One or more of rail (30, 46, 52) is inserted into one of the left and right channels 20, 24 (right channel 24 illustrated) of post 12. First and second self-tapping screws 83, 84 are inserted through the upper outer face 74 and a lower outer face 75. The screws 83, 84 further are inserted to upper sidewall 71R and lower sidewall 73R, respectively, and rail 46 to retain the rail to the post 12. Plugs 60 may be used to close the openings left by the screws 83, 84 passing through the outer faces 74, 75 of the post 12 outer wall 66.

[0044] In the event that post 12 is used as a corner post, a panel 16 will be connected to one of the left and right channels 20, 24 and another panel 16 will be connected to one of the outer faces 74, 75 so as to form an angled configuration, preferably perpendicular. It is further possible that one or more of channels 20, 24 will include a panel 16 and one or both of the outer faces 74, 75 will include an attached panel 16. Thus, the post 12 may be used in a number of fence assembly configurations wherein 1-4 fence panels may be secured to a single post.

[0045] When a panel 16 is attached to an outer face, it is advantageous to provide the face with an attachable channel member 85, as illustrated in FIG. 5, so as to provide the post outer face a structure to which the panel members may be attached in the same way as panel members are attached to the channels 20, 24 of the post 12. Accordingly, the channel member 85 is an elongate U-shaped channel member that is attached along an outer face 74, 75 (see FIG. 3) of post 12.

[0046] Standard self-tapping screws, as shown in FIG. 4, may be used to attach the channel member 85 to post 12. The channel member includes a back wall 86 and first and second channel sidewalls 87, 88. A panel (not shown) is attached in a similar fashion to that of FIG. 4, by attaching the channel member 85 the post, inserting the panel or panel member into the channel member and driving self-tapping screws inwardly through the channel sidewalls 87, 88 through the panel members.

[0047]FIG. 6 illustrates a filler member 89 of the present invention. The filler member 89 is a hollow elongate rectangular member in cross-section, sized and shaped to be received by channels 20 and 24 of post 12. The filler member 89 may be applied to the post 12 in order to fill one or more of the channels 20, 24 so as to present a relative smooth side of the post in the event that the channel is not used to receive panel components.

[0048] The filler member 89 may include a wood or metal or other suitable insert for enhanced structural, enhanced attachment and other reasons. In the event that the filler member 89 is inserted into a post 12 adjacent a gate of the fence, the filler may be provided with internal reinforcement, like a wood insert (not shown). The gate (not shown) may then be affixed to the filler and/or the post 12 by way of hinges, latches or the like. In the event that the fence is intended to abut a wall of a home or garage or the like, the filler member 89 and insert may be first attached to the wall. The post 12 is attached to the filler member 89. In this example, the filler and post (89, 12) may be referred to a lag post.

[0049]FIG. 7 illustrates a board member 36 of the present invention. The board member 36 is a hollow elongate rectangular member in cross-section. In one embodiment, the board member 36 is sized to have the dimensions of a 1×6 or any suitable dimension. The board member 36 may be used as one or more of a plurality of panel components, (See FIG. 1). It will be understood that board member 36 may be oriented in a vertical direction (as in FIG. 1) or horizontally.

[0050]FIG. 8 illustrates a hollow, generally rectangular, interlocking tongue-and-groove panel member 90 for use as a panel component. The interlocking member 90 includes an upper surface 91 with a tongue 92 extending from a central portion of the upper surface 91. A lower surface 93 opposite the upper surface 91 includes a groove 94 sized and shaped to receive a tongue 92 of an adjacent interlocking member or the like.

[0051]FIG. 9 illustrates an upper or top rail 52. Top rail 52 is a hollow generally rectangular panel component. A narrow top rail groove 56 is formed on an underside of the rail 52 sized to receive a narrow panel component such as a lattice member 54, for example. It will be understood that the top rail 52 may be used in a bottom position 32 of the panel 16 in the event that a narrow panel component is used in place of a component such as boards 36.

[0052]FIG. 10 illustrates an intermediate or mid-rail 46. Intermediate rail 46 is a generally rectangular panel component in cross-section and is intended to be oriented in a horizontally in the panel 16. The intermediate rail 46 may be positioned at a point in the panel 16 between the upper rail 30 and lower rail 58 to receive panel components therebetween. The intermediate rail 46 may include over channel 48 and under channel 42 as described above.

[0053]FIG. 11 illustrates a bottom rail 30. Bottom rail 30 is a hollow generally rectangular panel component. A bottom rail channel 34 is formed on an upper edge thereof. For example, the bottom rail channel 34 may receive one or more boards 36 depending on the orientation thereof. It will be understood that the bottom rail 30 may be used in an upper position of the panel 16 in the event that a wide panel component is used at the top of the panel 16.

[0054] While the apparatus and method herein disclosed forms a preferred embodiment of this invention, this invention is not limited to that specific apparatus and method, and changes can be made therein without departing from the scope of this invention, which is defined in the appended claims. 

What is claimed is:
 1. A post for a fence assembly comprising: an elongated member having an outer wall, said outer wall having a generally H-shaped cross-sectional shape including a first side and a second side, said first and second sides being oriented opposite each other; and one or more inner rib attached to an inner surface of said outer wall and extending between said first side and said second side to define a middle chamber of said elongated member.
 2. The post of claim 2 wherein said first side includes a first channel formed therealong and said second side includes a second channel formed therealong, both first and second channels being defined by said H-shaped cross-sectional shape.
 3. The post of claim 1 wherein said one or more inner ribs is a pair of spaced ribs.
 4. The post of claim 2 wherein said first channel includes a first upper sidewall, a first inner sidewall and a first lower sidewall.
 5. The post of claim 2 wherein said second channel includes a second upper sidewall, a second inner sidewall and a second lower sidewall.
 6. The post of claim 3 wherein a first of said pair of inner ribs extends between a first point and a second point on said inner surface of said outer wall.
 7. The post of claim 6 wherein said first point is adjacent an intersection of said first upper sidewall and said first inner sidewall and said second point is adjacent an intersection of said second upper sidewall and said second inner sidewall.
 8. The post of claim 6 wherein a second of said pair of inner ribs extends between a third point and a fourth point on said inner surface of said outer wall.
 9. The post of claim 8 wherein said third point is adjacent an intersection of said first inner sidewall and said first lower sidewall and said fourth point is adjacent an intersection of said second inner sidewall and said second lower sidewall.
 10. The post of claim 1 wherein said middle chamber has a rectangular cross-section.
 11. The post of claim 1 wherein said middle chamber is defined by said first and second ribs and said first and second inner walls.
 12. The post of claim 1 wherein said outer wall includes a generally planar third side and a fourth side of said elongated member.
 13. A post assembly for a fence comprising: an elongated post member having an outer wall, said outer wall having a generally H-shaped cross-sectional shape defining a first channel along a first side of said elongated member and a second channel along a second side of said elongated member, said first and second sides being oriented opposite each other; one or more inner rib attached to an inner surface of said outer wall and extending between said first side and said second side to define a middle chamber of said elongated member; and a reinforcing member shaped and sized to be received within said middle chamber for reinforcing said post member.
 14. The post assembly of claim 13 wherein said reinforcing member is a rectangle in cross section.
 15. The post assembly of claim 14 further comprising a rigid foot plate connected to a lower end of said reinforcing member.
 16. The post assembly of claim 15 wherein said foot plate is adapted to be fastened to a footing.
 17. A fence assembly comprising: a plurality of spaced, elongated post members, each of said plurality of elongated post members having an outer wall having a generally H-shaped cross-sectional shape, each of said plurality of elongated post members including a first side and a second side, said first and second sides being oriented opposite each other and one or more inner rib attached to an inner surface of said outer wall and extending between said first side and said second side to define a middle chamber of said elongated post member; one or more reinforcing member positioned in said middle chamber of one or more of said plurality of elongated hollow members to provide support thereto; and a plurality of fence panels fastened between adjacent pairs of said plurality of spaced, elongated post members.
 18. The fence assembly of claim 17 wherein said first side includes a first channel formed therealong and said second side includes a second channel formed therealong, both first and second channels being defined by said H-shaped cross-sectional shape.
 19. The fence assembly of claim 17 wherein said one or more inner ribs is a pair of spaced ribs.
 20. The fence assembly of claim 18 wherein said panels include one or more fence panel components.
 21. The fence assembly of claim 18 further comprising filler members sized and shaped to be received by one or both of said first channel and said second channel.
 22. The fence assembly of claim 18 further comprising one or more channel member attachable to said elongated post members and sized and shaped for receiving an edge of one of said plurality of fence panels. 